Recliner mechanism with mounting feature

ABSTRACT

A seat assembly is provided and may include a support member having a first surface, a second surface, and an aperture disposed between the first surface and the second surface. The first surface may be substantially coplanar with the second surface and a recliner mechanism may be received between the first surface and the second surface and may at least partially overlap the aperture.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/314,907, filed on Mar. 17, 2010 and claims the benefit of U.S.Provisional Application No. 61/415,539, filed on Nov. 19, 2010. Theentire disclosures of each of the above applications are incorporatedherein by reference.

FIELD

The present disclosure relates to recliner mechanisms and moreparticularly to a mounting feature of a recliner mechanism.

BACKGROUND

This section provides background information related to the presentdisclosure and is not necessarily prior art.

Seat assemblies typically include at least one recliner mechanism thatpermits selective rotation of a seatback relative to a seat bottom. Suchrecliner mechanisms permit rotation of the seatback relative to the seatbottom to position the seatback relative to the seat bottom in a desiredangular position. Furthermore, such recliner mechanisms may also permitthe seatback to be positioned in a fold-flat state relative to the seatbottom to allow the seatback and seat bottom to be moved into a dumpedposition and/or to allow the seatback to provide a flat-load surface.

Regardless of the particular construction and function of the reclinermechanism, conventional recliner mechanisms are typically disposedproximate to a pivot point disposed between the seatback and the seatbottom. The recliner mechanism may be attached to either or both of theseatback and the seat bottom to selectively permit rotation of theseatback relative to the seat bottom.

With particular reference to FIG. 1, a prior-art recliner mechanism A isshown incorporated into and attached to a seatback-support member B. Therecliner mechanism A is received generally within a stepped portion C ofthe seatback-support member B and at least a portion of the reclinermechanism A is fixedly attached to the seatback-support member B withinthe stepped portion C. The stepped portion C includes a surface D thatis offset from a surface E of the seatback-support member B by adistance F. The surface E is located above the stepped portion C andextends generally to a top portion of the seatback-support member B andaway from the recliner mechanism A. The surface D of the stepped portionC is disposed proximate to a bottom portion of the seatback-supportmember B and proximate to a seat bottom (not shown).

The stepped portion C provides a recess G in which the reclinermechanism A is disposed. The recess G accounts for most if not all ofthe thickness of the recliner mechanism A and provides a surface D towhich at least a portion of the recliner mechanism A may be fixedlyattached.

While the recess G of the seatback-support member B provides a surface Dfor attachment to the recliner mechanism A, as well as a space in whichto receive the recliner mechanism A, the stepped portion C typicallyrequires the seatback-support member B to be formed from a relativelythick material to ensure adequate strength of the seatback-supportmember B at a transition area H disposed generally between surface E andsurface D. Forming the seatback-support member B from a relatively thickmaterial increases the weight, size, and cost of the seatback-supportmember B and, as a result, increases the overall weight, size, and costof the assembled recliner mechanism and seatback-support member.

In addition to the foregoing, conventional recliner mechanisms typicallyrequire a separate and distinct mounting bracket to attach a portion ofthe recliner mechanism to a seatback-support member and a separate anddistinct mounting bracket to attach a portion of the recliner mechanismto a structure of a seat bottom. While the respective mounting bracketsadequately attach a conventional recliner mechanism to aseatback-support structure and a seat bottom-support structure, suchbrackets increase the overall weight, cost, and complexity of theassembled recliner mechanism, seatback-support member, and seatbottom-support member.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

A seat assembly is provided and may include a support member having afirst surface, a second surface, and an aperture disposed between thefirst surface and the second surface. The first surface may besubstantially coplanar with the second surface and a recliner mechanismmay be received between the first surface and the second surface and mayat least partially overlap the aperture.

In another form, the present disclosure provides a seat assembly thatmay include a support member, a recliner mechanism and an encapsulationmember. The support member may include a first surface, a secondsurface, and an aperture disposed between the first surface and thesecond surface. The first surface may be substantially coplanar with thesecond surface. The recliner mechanism may be received between the firstsurface and the second surface and may be disposed substantially coaxialwith the aperture. The encapsulation member may engage the supportmember and the recliner mechanism.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a schematic representation of a prior-art recliner mechanismincorporated into a prior-art, seatback-support member;

FIG. 2 is a perspective view of a seat assembly incorporating aseatback-support member and recliner mechanism in accordance with theprinciples of the present disclosure;

FIG. 3 is a perspective view of the seat assembly of FIG. 2 with part ofan outer structure removed to show the seatback-support member andrecliner mechanism of FIG. 2;

FIG. 4 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 5 is a partial sectional view of the seatback-support member andrecliner mechanism of FIG. 4;

FIG. 6 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 7 is a partial cross-sectional view of the seatback-support memberand recliner mechanism of FIG. 6;

FIG. 8 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 9 is a partial cross-sectional view of the seatback-support memberand recliner mechanism of FIG. 8;

FIG. 10 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 11 is a partial cross-sectional view of the seatback-support memberand recliner mechanism of FIG. 10;

FIG. 12 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 13 is a partial perspective view of the seatback-support member andrecliner mechanism of FIG. 12;

FIG. 14 is a partial cross-sectional view of the seatback-support memberand recliner mechanism of FIGS. 12 and 13;

FIG. 15 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 16 is a partial cross-sectional view of a seatback-support memberand recliner mechanism of FIG. 15;

FIG. 17 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 18 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 19 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 20 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 21 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 22 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 23 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 24 is a partial perspective view of the seat-back support memberand recliner mechanism of FIG. 23;

FIG. 25 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure;

FIG. 26 is a partial exploded view of the seatback-support member andrecliner mechanism of FIG. 25;

FIG. 27 is a cross-sectional view of the seatback-support member andrecliner mechanism of FIG. 25;

FIG. 28 is a partial perspective view of a seatback-support member inaccordance with the principles of the present disclosure for use withthe seat assembly of FIG. 2 and incorporating a recliner mechanism inaccordance with the principles of the present disclosure; and

FIG. 29 is a cross-sectional view of the seatback-support member andrecliner mechanism of FIG. 28.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

With reference to FIGS. 2-5, a seat assembly 2 for a vehicle is providedand may include a seatback 4, a seat bottom 6, a head restraint 8, and arecliner mechanism 10. The seatback 2 and seat bottom 4 may include aseatback-side member 12 and a seat-bottom-side member 13. The reclinermechanism 10 cooperates with and is supported by the seatback-sidemember 12 to selectively permit movement of the seatback-side member 12relative to the seat-bottom-side member 13 about an axis defined by therecliner mechanism 10.

The recliner mechanism 10 may be a round recliner and may include aguide plate 14, a ratchet plate 16, a locking mechanism 18, and anencapsulation ring 20. The recliner mechanism 10 may also include a cam22 and a biasing member 24 that cooperate to bias the locking mechanism18 into a locked state. A lever (not shown) may engage the cam 22 forrotation therewith between the locked state and an unlocked state. Whenthe locking mechanism 18 is in the locked state, relative rotationbetween the guide plate 14 and the ratchet plate 16 is restricted by thelocking mechanism 18. When the locking mechanism 18 is in the unlockedstate, relative rotation between the guide plate 14 and the ratchetplate 16 the locking mechanism 18 allows relative rotation between theguide plate 14 and the ratchet plate 16, and thus, relative rotationbetween the seatback 4 and the seat bottom 6. A user may grasp androtate the lever to rotate the cam 22 to cause the locking mechanism 18to move between the locked and unlocked states. The recliner mechanism10 may be of the type disclosed in assignee's commonly ownedInternational Application No. PCT/US2009/033067 filed Feb. 4, 2009,which claims benefit of U.S. Provisional Application No. 61,026,352filed Feb. 5, 2008; and International Application No. PCT/US2009/031255filed Jan. 16, 2009, which claims benefit of U.S. ProvisionalApplication No. 61/021,744 filed Jan. 17, 2008, and U.S. ProvisionalApplication No. 61/044,162 filed Apr. 11, 2008, the disclosures of whichare herein incorporated by reference.

As shown in FIG. 5, the locking mechanism 18 is disposed generallybetween the guide plate 14 and the ratchet plate 16. The encapsulationring 20 may surround at least a portion of the guide plate 14 andratchet plate 16 and may include a main body 26 surrounding at least aportion of a perimeter of the guide plate 14 and ratchet plate 16, afirst flange 28, and a second flange 30. The first flange 28 may bepositioned substantially perpendicular to the main body 26 and mayextend over a portion of the guide plate 14. The second flange 30 maylikewise be formed substantially perpendicular to the main body 26 andmay extend in an opposite direction than the first flange 28.

The seatback-side member 12 may include a main body 32, a flange 34, andan aperture 36. The flange 34 may be formed substantially perpendicularto the main body 32 and may extend at least partially around a perimeterof the main body 32. The aperture 36 may be formed through the main body32 and may be spaced apart and separated from the flange 34.

The main body 32 may surround the aperture 36 and may include a firstsurface 38 and a second surface 40. The first surface 38 may be formedon an opposite side of the aperture 36 than the second surface 40 suchthat the aperture 36 extends generally between the first surface 38 andthe second surface 40. In one configuration, the first surface 38 issubstantially coplanar with the second surface 40.

With particular reference to FIGS. 3-5, attachment of the reclinermechanism 10 to the seatback-side member 12 will be described in detail.Once the recliner mechanism 10 is assembled such that the guide plate14, ratchet plate 16, and locking mechanism 18 are assembled to theencapsulation ring 20, the recliner mechanism 10 may be attached to theseatback-side member 12. The recliner mechanism 10 may be inserted intothe aperture 36 of the seatback-side member 12 such that theencapsulation ring 20 extends from the first surface 38 and the secondsurface 40 of the seatback-side member 12.

The recliner mechanism 10 may be inserted into the aperture 36 until thesecond flange 30 of the encapsulation ring 20 contacts the main body 32at a third surface 42 and a fourth surface 44. The third surface 42 maybe formed on an opposite side of the main body 32 than the first surface38 while the fourth surface 44 may be formed on an opposite side of themain body 32 than the second surface 40. As such, the first surface 38is substantially parallel to the third surface 42 and the second surface40 is substantially parallel to the fourth surface 44. As with the firstsurface 38 and the second surface 40, the third surface 42 may besubstantially coplanar with the fourth surface 44.

Once the second flange 30 contacts the third surface 42 and the fourthsurface 44 of the main body 32, the second flange 30 of theencapsulation ring 20 may be attached to the main body 32 at the thirdsurface 42 and the fourth surface 44 via a suitable process such as, forexample, M.I.G. welding or laser welding. In one configuration, thesecond flange 30 is laser welded around an entire perimeter of thesecond flange 30. In some configurations, the second flange 30 may bewelded to the main body 32 at discrete locations or attached via one ormore rivets or any other suitable means.

Once the second flange 30 is attached to the main body 32, the main body32 is fixed for movement with the encapsulation ring 20. Furthermore,because the ratchet plate 16 is fixed for movement with theencapsulation ring 20 at an outer perimeter of the ratchet plate 16, theratchet plate 16 is likewise fixed for movement with the main body 32 ofthe seatback-side member 12. In one configuration, the ratchet plate 16is attached to the encapsulation ring 20 at a weld 46 disposed at anouter perimeter of the ratchet plate 16 and generally between the outerperimeter of the ratchet plate 16 and the main body 26 of theencapsulation ring 20.

While the ratchet plate 16 is described as being attached to theencapsulation ring 20 such that the ratchet plate 16 is fixed formovement with the encapsulation ring 20 and, thus, the seatback-sidemember 12, the guide plate 14 could alternatively be attached to theencapsulation ring 20 such that the guide plate 14 is fixed for movementwith the encapsulation ring 20 and seatback-side member 12. Further,while the encapsulation ring 20 is described as being attached to theseatback-side member 12, the encapsulation ring 20 could alternativelybe attached to the seat-bottom side member 13 in a similar fashion asdescribed with respect to the seatback-side member 12 such that eitherthe guide plate 14 or ratchet plate 16 are fixed for movement with theseat-bottom side member 13 via the encapsulation ring 20. While theencapsulation ring 20 could be attached to either the guide plate 14 orthe ratchet plate 16 and the guide plate 14 or ratchet plate 16 could beassociated with either the seatback-side member 12 or the seat-bottomside member 13, the encapsulation ring 20 will be described and shownhereinafter in each configuration of the recliner mechanism 10-10 m asbeing attached to the ratchet plate 16 and, thus, the ratchet plate 16will be described and shown as being attached to the seatback-sidemember 12.

The recliner mechanism 10 may be directly attached to the seatback-sidemember 12 without requiring an additional support bracket. Permittingthe encapsulation ring 20 of the recliner mechanism 10 to attach therecliner mechanism 10 to the seatback-side member 12 reduces the overallsize of the assembled recliner mechanism 10 and seatback-side member 12.Further, by obviating the need for a support bracket to attach therecliner mechanism 10 to the seatback-side member 12, the overall weightand cost of the assembled recliner mechanism 10 and seatback-side member12 may be reduced.

The assembled recliner mechanism 10 and seatback-side member 12 may beattached to the seat-bottom side member 13. Specifically, the guideplate 14 may be attached to the seat-bottom side member 13, for example,such that the guide plate 14 is fixed for movement with the seat-bottomside member 13.

In operation, when the locking mechanism 18 permits relative movementbetween the guide plate 14 and the ratchet plate 16, the ratchet plate16, seatback-side member 12, and encapsulation ring 20 are permitted torotate relative to the guide plate 14. Permitting rotation of theseatback-side member 12, ratchet plate 16, and encapsulation ring 20relative to the seat bottom likewise permits adjustment of a position ofthe seatback-side member 12 relative to the seat bottom. Because theseatback-side member 12 may support the seatback 4, permitting movementof the seatback-side member 12 relative to the seat-bottom side member13 likewise permits movement and adjustment of a position of theseatback 4 relative to the seat bottom 6.

The recliner mechanism 10 may be disposed proximate to a bottom portionof the seatback-side member 12 such that the recliner mechanism 10 is inclose proximity to the seat bottom 6 when the seatback-side member 12 isattached to the seat bottom 6. As such, the main body 32 proximate tothe first surface 38 and the third surface 42 may extend generally awayfrom the recliner mechanism 10 towards a top portion of theseatback-side member 12 while the second surface 40 and fourth surface44 of the main body 32 may extend generally away from the reclinermechanism 10 and toward the seat bottom 6.

With reference to FIGS. 6 and 7, a recliner mechanism 10 a is shownincorporated into a seatback-side member 12 a. In view of thesubstantial similarity in structure and function of the componentsassociated with the recliner mechanism 10 and seatback-side member 12with respect to the components associated with the recliner mechanism 10a and seatback-side member 12 a, like reference numerals are usedhereinafter in the drawings to identify like components while likereference numerals containing letter extensions are used to identifythose components that have been modified.

As with the recliner mechanism 10, the recliner mechanism 10 a mayinclude a guide plate 14, a ratchet plate 16, and a locking mechanism18. The recliner mechanism 10 a may also include an encapsulation ring20 a including a main body 26 a and a first flange 28. The main body 26a may be formed substantially perpendicular to the first flange 28 andmay extend around at least a portion of an outer perimeter of the guideplate 14 and the ratchet plate 16.

The seatback-side member 12 a may include a main body 32 a including anaperture 36 a. The aperture 36 a may be formed in the main body 32 a andmay be defined by extruding or otherwise forming portions of the mainbody 32 a into the aperture 36 a. Specifically, portions of the mainbody 32 a disposed proximate to the aperture 36 a may be bent orotherwise formed at a substantially ninety-degree (90°) angle such thatthe portions of the main body 32 a proximate to the aperture 36 a areperpendicular to the main body 32 a. The bent or otherwise formedportions of the main body 32 a may define a flange 48 that issubstantially perpendicular to the first, second, third, and fourthsurfaces 38, 40, 42, and 44 of the main body 32 a and extendssubstantially in the same direction as the flange 34.

With particular reference to FIG. 7, assembly of the recliner mechanism10 a to the seatback-side member 12 a will be described in detail. Oncethe guide plate 14, ratchet plate 16, and locking mechanism 18 arereceived within the encapsulation ring 20 a, the recliner mechanism 10 amay be inserted into the aperture 36 a of the seatback-side member 12 a.The recliner mechanism 10 a may be inserted into the aperture 36 a suchthat the main body 26 a of the encapsulation ring 20 a opposes and isaligned with the flange 48 of the main body 32 a. The encapsulation ring20 a may be positioned relative to the flange 48 such that the main body26 a of the encapsulation ring 20 a opposes and is in contact with theflange 48 of the seatback-side member 12 a. In other words, the mainbody 26 a of the encapsulation ring 20 a may be substantially parallelto the flange 48 and may be fixedly attached thereto via a weld 50, forexample.

Positioning the recliner mechanism 10 a within the aperture 36 a andflange 48 allows the recliner mechanism 10 a and seatback-side member 12to include a reduced overall width when compared to a width of aconventional recliner mechanism/seatback-side member assembly (FIG. 1).Furthermore, positioning the recliner mechanism 10 a at least partiallywithin the aperture 36 a allows the first surface 38 and third surface42 to be substantially within the same plane and allows the secondsurface 40 and fourth surface 44 to be substantially within the sameplane, thereby obviating the need for a stepped portion associated withconventional seatback-side members (FIG. 1). Providing the reclinermechanism 10 a within the flange 48 also allows the recliner mechanism10 a to increase the overall strength of the seatback-side member 12 a,as the flange 48 is attached to the encapsulation ring 20 a.

As with the recliner mechanism 10, during operation, the ratchet plate16 may be fixed for rotation with the seatback-side member 12 a due toengagement between the ratchet plate 16 and the encapsulation ring 20 a.As with the recliner mechanism 10, the encapsulation ring 20 a may befixedly attached to the ratchet plate 16 via a weld 46.

With reference to FIGS. 8 and 9, a recliner mechanism 10 b is shownincorporated into a seatback-side member 12 b. In view of thesubstantial similarity in structure and function of the componentsassociated with the recliner mechanism 10 and seatback-side member 12with respect to the recliner mechanism 10 b and seatback-side member 12b, like reference numerals are used hereinafter and in the drawings toidentify like components while like reference numerals containing letterextensions are used to identify those components that have beenmodified.

The recliner mechanism 10 b may include a guide plate 14, a ratchetplate 16, and a locking mechanism 18. An encapsulation ring 20 b maysurround at least a portion of the guide plate 14, ratchet plate 16, andlocking mechanism 18 and may include a main body 26 b and a first flange28. The first flange 28 may be formed substantially perpendicular to themain body 26 b and may extend at least partially around a top portion ofthe guide plate 14, as shown in FIG. 9. The main body 26 b may be formedsubstantially perpendicular to the first flange 28 and may extend atleast partially around an outer perimeter of the guide plate 14 andratchet plate 16.

The seatback-side member 12 may include an aperture 36 b having a flange48 b. The flange 48 b may be formed in an opposite direction than theflange 48 such that the flange 48 b extends in an opposite direction ofthe flange 34 of the seatback-side member 12 b.

When the recliner mechanism 10 b is assembled to the seatback-sidemember 12 b, the recliner mechanism 10 b is received generally withinthe aperture 36 b of the seatback-side member 12 b such that the mainbody 26 b of the encapsulation ring 20 b opposes the flange 48 b. Aswith the recliner mechanism 10 a, the main body 26 b of theencapsulation ring 20 b may be fixedly attached to the seatback-sidemember 12 b at the flange 48 b by providing a weld 50 generally betweenthe main body 26 b of the encapsulation ring 20 b and the flange 48 b ofthe seatback-side member 12 b.

As with the recliner mechanisms 10 and 10 a, once the encapsulation ring20 b is attached to the seatback-side member 12 b, the seatback-sidemember 12, ratchet plate 16, and encapsulation ring 20 may be fixed forrotation, as the ratchet plate 16 may be attached to the encapsulationring 20 b via a weld 46.

With reference to FIGS. 10 and 11, a recliner mechanism 10 c is shownattached to a seatback-side member 12 c. In view of the substantialsimilarity in structure and function of the components associated withthe recliner mechanism 10 and the seatback-side member 12 with respectto the recliner mechanism 10 c and the seatback-side member 12 c, likereference numerals are used hereinafter in the drawings to identify likecomponents while like reference numerals containing letter extensionsare used to identify those components that have been modified.

The recliner mechanism 10 c may include a guide plate 14, a ratchetplate 16, and a locking mechanism 18. An encapsulation ring 20 c maysurround at least a portion of the guide plate 14 and the ratchet plate16 and may include a main body 26 c and a second flange 30 c. Inaddition to the encapsulation ring 20 c, the recliner mechanism 10 c mayalso include a mounting bracket 52 disposed generally between theencapsulation ring 20 c and the seatback-side member 12 c. The mountingbracket 52 may include a main body 54, an aperture 56 formed through themain body 54, and a flange 58 disposed around an outer perimeter of themain body 54. The flange 58 may be offset from the main body 54 suchthat a recess 60 is defined generally between the flange 58 and the mainbody 54.

When the mounting bracket 52 is attached to the recliner mechanism 10 c,a portion of the recliner mechanism 10 c may be disposed generallywithin the recess 60. Specifically, the ratchet plate 16 may be disposedwithin and attached to the main body 54 within the recess 60.

The seatback-side member 12 c may include an aperture 36 c and may be ofa similar construction to the seatback-side member 12.

With particular reference to FIG. 11, assembly of the recliner mechanism10 c to the seatback-side member 12 c will be described in detail. Oncethe mounting bracket 52 is attached to the encapsulation ring 20 cand/or ratchet plate 16, the mounting bracket 52 and, thus, the reclinermechanism 10 c, may be attached to the seatback-side member 12 c.Specifically, the main body 54 of the mounting bracket 52 may be atleast partially received within the aperture 36 c of the seatback-sidemember 12 c. Because the flange 58 is offset from the main body 54, theflange 58 may contact the first surface 38 and second surface 40 of theseatback-side member 12 c to position the mounting bracket 52 andrecliner mechanism 10 c relative to the seatback-side member 12 c.

Once the flange 58 engages the first surface 38 and the second surface40 of the seatback-side member 12 c, the flange 58 may be fixedlyattached to the seatback-side member 12 c. In one configuration, a weldextends generally around an entire perimeter of the mounting bracket 52at the flange 58 to fixedly attach the flange 58 to the main body 32 ofthe seatback-side member 12 c. In another configuration, the mountingbracket 52 may be attached to the seatback-side member 12 at discretelocations. In either configuration, the flange 58 may be fixedlyattached to the seatback-side member 12 by a suitable process such as,for example, M.I.G. welding or laser welding.

While the mounting bracket 52 is shown in FIG. 10 as including anarcuate surface 62 and a substantially planar surface 64, the mountingbracket 52 could alternatively include a substantially circular shape.The mounting bracket 52 may include any shape that allows the mountingbracket to be nested within a stamping tool or other manufacturingprocess that minimizes scrap when the mounting bracket 52 is formed.

With reference to FIGS. 12-14, a recliner mechanism 10 d andseatback-side member 12 d are provided. In view of the substantialsimilarity in structure and function of the components associated withthe recliner mechanism 10 and the seatback-side member 12 with respectto the recliner mechanism 10 d and seatback-side member 12 d, likereference numerals are used hereinafter in the drawings to identify likecomponents while like reference numerals containing letter extensionsare used to identify those components that have been modified.

The recliner mechanism 10 d may include a guide plate 14, a ratchetplate 16, and a locking mechanism 18. An encapsulation ring 20 d mayextend around and partially overlap a perimeter of the guide plate 14and the ratchet plate 16 and may include a main body 26 d and a secondflange 30 d. The second flange 30 d may be formed substantiallyperpendicular to the main body 26 d and may at least partially overlap asurface of the ratchet plate 16, as shown in FIG. 14.

The seatback-side member 12 d may include a so-called “doubler plate”that increases the overall strength of the seatback-side member 12proximate to an aperture 36 d. In one configuration, the doubler plateis formed by folding a main body 32 d of the seatback-side member 12 donto itself in an area proximate to the aperture 36 d such that theseatback-side member 12 d includes a localized region of increasedthickness. While the doubler plate is described as being formed byfolding the main body 32 d such that the main body 32 d is folded ontoitself to substantially double a thickness of the seatback-side member12 d in an area of the aperture 36 d, the seatback-side member 12 dcould alternatively be provided with a separate bracket or plate that isfixedly attached to the main body 32 d of the seatback-side member 12 dto locally reinforce the seatback-side member 12 d proximate to theaperture 36 d.

When the recliner mechanism 10 d is attached to the seatback-side member12 d, the ratchet plate 16 may be fixedly attached to the main body 32 dof the seatback-side member 12 d by any suitable method. For example, inone configuration, the ratchet plate 16 may include a series ofprotrusions 66 matingly received within apertures 68 formed in the mainbody 32 d of the seatback-side member 12 d. Once the protrusions 66 arereceived within the aperture 68, the ratchet plate 16 may be fixedlyattached to the main body 32 d by welding the ratchet plate 16 to themain body 32 d. Once the ratchet plate 16 is fixedly attached to themain body 32 d of the seatback-side member 12 d, the ratchet plate 16 isfixed for movement with the seatback-side member 12 d.

With reference to FIGS. 15 and 16, a recliner mechanism 10 e andseatback-side member 12 e are provided. In view of the substantialsimilarity in structure and function of the components associated withthe recliner mechanism 10 and the seatback-side member 12 with respectto the recliner mechanism 10 e and seatback-side member 12 e, likereference numerals are used hereinafter and in the drawings to identifylike components while like reference numerals containing letterextensions are used to identify those components that have beenmodified.

The recliner mechanism 10 e may include a guide plate 14, a ratchetplate 16, and a locking mechanism 18. An encapsulation ring 20 e mayextend around and partially overlap a perimeter of the guide plate 14and the ratchet plate 16 and may include a main body 26 e, a firstflange 28, and a second flange 30 e. The second flange 30 e may beformed substantially perpendicular to the main body 26 e and may atleast partially overlap a surface of the ratchet plate 16.

As shown in FIG. 16, the second flange 30 e may include a substantiallyhexagonal shape having six substantially planar sides 70. The planarsides 70 may each be connected to one another via a radiused edge 72 or,alternatively, may provide the second flange 30 e with six substantiallysharp corners (not shown) formed by the intersection of a pair ofadjacent planar sides 70. Regardless of the particular configuration ofthe second flange 30 e, the hexagonal shape allows the encapsulationring 20 e to nest with other encapsulation rings 20 e during formationof the encapsulation rings 20 e and, as such, reduces the scrapassociated with producing each encapsulation ring 20 e.

With continued reference to FIGS. 15 and 16, installation of therecliner mechanism 10 e into the seatback-side member 12 e will bedescribed. The recliner mechanism 10 e may be positioned relative to theseatback-side member 12 e such that the encapsulation ring 20 e isreceived at least partially within an aperture 36 formed in theseatback-side member 12 e. Once the encapsulation ring 20 e ispositioned within the aperture 36 such that an outer surface of the mainbody 26 e opposes the aperture 36, a weld 50 may be used at variouslocations around the second flange 30 e to attach the second flange 30 eand, thus, the encapsulation ring 20 e, to the seatback-side member 12e. Specifically, once the second flange 30 e engages the third andfourth surfaces 42, 44 of the seatback-side member 12 e, the welds 50may be utilized to attach the second flange 30 e to the surfaces 42, 44.Because the encapsulation ring 20 e may be attached to the ratchet plate16 via a weld 46, attaching the encapsulation ring 20 e to theseatback-side member 12 e likewise attaches the guide plate 14, ratchetplate 16, and locking mechanism 18 of the recliner mechanism 10 e to theseatback-side member 12 e. While the guide plate 14, ratchet plate 16,locking mechanism 18, and encapsulation ring 20 e are supported by theseatback-side member 12, only the ratchet plate 16 and encapsulationring 20 e are fixed for rotation with the seatback-side member 12 e, asthe encapsulation ring 20 e is attached to the ratchet plate 16 via weld46 and is attached to the seatback-side member 12 e via weld 50.

While the seatback-side member 12 e is described as being associatedwith a recliner mechanism 10 e having an encapsulation ring 20 eincorporating a substantially hexagonal second flange 30 e, theseatback-side member 12 e could be associated with a recliner mechanismhaving an encapsulation ring incorporating a second flange of virtuallyany geometrical shape. FIGS. 17-24 provide various recliner mechanisms10 f-10 l incorporating encapsulation rings 20 f-20 l, each having asecond flange 30 f-30 l that may be attached to a respectiveseatback-side member 12 f-12 l. Each encapsulation ring 20 f-20 l mayinclude a shape that allows the particular ring 20 f-20 l to nest withother similarly shaped encapsulation rings 20 f-20 l to allow theencapsulation rings 20 f-20 l to nest during manufacturing, therebyreducing the scrap associated with forming each encapsulation ring 20f-20 l.

In view of the substantial similarity in structure and function of thecomponents associated with the recliner mechanism 10 and theseatback-side member 12 with respect to the recliner mechanisms 10 f-10l and the seatback-side members 12 f-12 l, like reference numerals areused hereinafter and in the drawings to identify like components whilelike reference numerals containing letter extensions are used toidentify those components that have been modified.

With reference to FIG. 17, the recliner mechanism 10 f is shown toinclude an encapsulation ring 20 f having a second flange 30 f. Thesecond flange 30 f may be attached to a seatback-side member 12 f via aweld 50 and may include three tabs 76. The three tabs 76 may include anouter surface 77. The outer surface 77 of one of the tabs 76 may engagea flange 84 of the seatback-side member 12 f to locate and position therecliner mechanism 10 f relative to the seatback-side member 12 f. Thewelds 50 may attach the encapsulation ring 20 f to the seatback-sidemember 12 f at one or more of the tabs 76 and/or at areas of the secondflange 30 f generally between the tabs 76. As with the foregoingrecliner mechanisms 10-10 e, attaching the encapsulation ring 20 f tothe seatback-side member 12 f fixes the ratchet plate 16 andencapsulation ring 20 f for movement with the seatback-side member 12 f.

With reference to FIG. 18, the recliner mechanism 10 g is shown as beingassociated with a seatback-side member 12 g and may include anencapsulation ring 20 g having a second flange 30 g. The second flange30 g may include a pair of tabs 78 extending therefrom. The tabs 78 maybe positioned adjacent to the seatback-side member 12 g to position therecliner mechanism 10 g relative to the seatback-side member 12 g. Forexample, an outer surface 79 of at least one tab 78 may engage a flange84 of the seatback-side member 12 g to locate and position the reclinermechanism 10 g relative to the seatback-side member 12 g.

At least one weld may secure the encapsulation ring 20 g to theseatback-side member 12 g at one or both of the tabs 78. While at leastone of the tabs 78 are described as being attached to the seatback-sidemember 12 g via at least one weld, an additional or alternative one ormore welds may be positioned in an area of the second flange 30 ggenerally between the tabs 78. Regardless of the particular location andnumber of welds used to secure the encapsulation ring 20 g to theseatback-side member 12 g, once the encapsulation ring 20 g is fixed tothe seatback-side member 12 g, the ratchet plate 16 and encapsulationring 20 g are fixed for movement with the seatback-side member 12 g, asdescribed above with respect to the recliner mechanisms 10-10 f.

With reference to FIG. 19, the recliner mechanism 10 h is shown as beingassociated with a seatback-side member 12 h and includes anencapsulation ring 20 h having a substantially rectangular shape. Theencapsulation ring 20 h may include a second flange 30 h that definesthe substantially rectangular shape of the encapsulation ring 20 h andmay be attached to the seatback-side member 12 via at least one weld 50at the second flange 30 h. The at least one weld 50 may be located atvarious points along the second flange 30 h to attach the second flange30 h and, thus, the encapsulation ring 20 h and recliner mechanism 10 hto the seatback-side member 12 h. As with the recliner mechanisms 10-10g, attaching the second flange 30 h to the seatback-side member 12 hfixes the ratchet plate 16 and encapsulation ring 20 h for movement withthe seatback-side member 12 h.

With reference to FIG. 20, the recliner mechanism 10 i is shown as beingassociated with a seatback-side member 12 i and includes anencapsulation ring 20 i having a substantially square shape. Theencapsulation ring 20 i may include a second flange 30 i that definesthe substantially square shape of the encapsulation ring 20 i and may beattached to the seatback-side member 12 via at least one weld 50 at thesecond flange 30 i. The at least one weld 50 may be located at variouspoints along the second flange 30 i to attach the second flange 30 iand, thus, the encapsulation ring 20 i and recliner mechanism 10 i tothe seatback-side member 12 i. As with the recliner mechanisms 10-10 h,attaching the second flange 30 i to the seatback-side member 12 i fixesthe ratchet plate 16 and encapsulation ring 20 i for movement with theseatback-side member 12 i.

With reference to FIG. 21, the recliner mechanism 10 j is shown as beingassociated with a seatback-side member 12 j and may include anencapsulation ring 20 j having a series of tabs 80. The encapsulationring 20 j may include a second flange 30 j that defines each tab 80 andmay be positioned relative to the seatback-side member 12 j such that atleast one weld attaches the encapsulation ring 20 j to the seatback-sidemember 12 j. The at least one weld may attach the second flange 30 j tothe seatback-side member 12 j at one or more of the tabs 80 and/or at anarea of the second flange 30 j disposed between the tabs 80 j.Regardless of the particular number and location of the welds, the weldsserve to attach the encapsulation ring 20 j to the seatback-side member12 j and, as with the recliner mechanisms 10-10 i, fix the ratchet plate16 and encapsulation ring 20 j for movement with the seatback-sidemember 12 j.

The tabs 80 may each include an outer arcuate surface 82 having asimilar radius to that of a flange 84 of the seatback-side member 12 j.At least one of the arcuate surfaces 82 may abut the flange 84 of theseatback-side member 12 j to aid in positioning the encapsulation ring20 j and, thus, the recliner mechanism 10 j, relative to theseatback-side member 12 j prior to attaching the encapsulation ring 20 jto the seatback-side member 12 j.

With reference to FIG. 22, the recliner mechanism 10 k is shown as beingassociated with a seatback-side member 12 k and may include anencapsulation ring 20 k. The encapsulation ring 20 k may include asecond flange 30 k having a pair of projections 88 that may serve toboth position the encapsulation ring 20 k relative to the seatback-sidemember 12 j and provide a surface for attaching the encapsulation ring20 j to the seatback-side member 12 j.

The pair of projections 88 may be disposed on opposite sides of a recess90 formed in the seatback-side member 12 j. Positioning the projections88 on either side of the recess 90 and allowing either or bothprojections 88 to contact an area of the seatback-side member 12 jproximate to the recess 90 allows the projections 88 to aid in properlypositioning the encapsulation ring 20 k and, thus, the reclinermechanism 10 k, relative to the seatback-side member 12 j. Once theencapsulation ring 20 k and recliner mechanism 10 k are properlypositioned relative to the seatback-side member 12 k, at least one weld50 may be used to attach the encapsulation ring 20 k to theseatback-side member 12 k at any location of the second flange 30 k. Asdescribed above with respect to the recliner mechanisms 10-10 j,attaching the encapsulation ring 20 k to the seatback-side member 12 kfixes the ratchet plate 16 and encapsulation ring 20 k for movement withthe seatback-side member 12 k.

With reference to FIGS. 23-24, the recliner mechanism 10 l is shown asbeing associated with a seatback-side member 12 l. The reclinermechanism 10 l may include an encapsulation ring 20 l having a secondflange 30 l that may position the recliner mechanism 10 l relative tothe seatback-side member 12 l and may provide a surface for attachingthe encapsulation ring 20 l to the seatback-side member 12 l.

The second flange 30 l may include a substantially tear-drop shapehaving a distal end 92 extending generally away from the guide plate 14and ratchet plate 16. The distal end 92 may be received within a recess94 formed in the seatback-side member 12 to aid in positioning theencapsulation ring 20 l and, thus, the recliner mechanism 10 l, relativeto the seatback-side member 12 l. Once the recliner mechanism 10 l isproperly positioned relative to the seatback-side member 12 l, at leastone weld 50 may attach the encapsulation ring 20 l and, thus, therecliner mechanism 10 l, to the seatback-side member 12 l. As with therecliner mechanisms 10-10 k, attaching the encapsulation ring 20 l inthis manner fixes the ratchet plate 16 and encapsulation ring 20 l formovement with the seatback-side member 12 l.

With reference to FIGS. 25-27, a recliner mechanism 10 m is shownincorporated into a seatback-side member 12 m. In view of thesubstantial similarity in structure and function of the componentsassociated with the recliner mechanism 10 and seatback-side member 12with respect to the components associated with the recliner mechanism 10m and seatback-side member 12 m, like reference numerals are usedhereinafter in the drawings to identify like components while likereference numerals containing letter extensions are used to identifythose components that have been modified.

As with the recliner mechanism 10, the recliner mechanism 10 m mayinclude a guide plate 14, a ratchet plate 16, and a locking mechanism18. The recliner mechanism 10 m may also include an encapsulation ring20 m including a main body 26 m, a first flange 28 m, and a secondflange 30 m. The main body 26 m may be formed substantiallyperpendicular to the first and second flanges 28 m, 30 m and may extendaround at least a portion of an outer perimeter of the guide plate 14and the ratchet plate 16.

The second flange 30 m may include a substantially helical shape havinga first end 31 and a second end 33. The second flange 30 m may includefirst and second cutouts 35, 37 disposed about one-hundred-eightydegrees (180°) apart from each other. The first cutout 35 may radiallyand axially separate the first and second ends 31, 33 from each other.The first and second cutouts 35, 37 may cooperate to define first andsecond portions 39, 41 of the second flange 30 m. Because of thesubstantially helical shape of the second flange 30 m, the second end 33is axially spaced apart from the first flange 28 m more than the firstend 31 is axially spaced apart from the first flange 28 m.

The seatback-side member 12 m may include a main body 32 m including anaperture 36 m and first, second, third and fourth surfaces 38, 40, 42,44. The main body 32 m may also include a flange 48 m at least partiallydefining the aperture 36 m. The flange 48 m may include a substantiallyhelical shape having a pitch that substantially matches a pitch of thehelical shape of the second flange 30 m of the encapsulation ring 20 m.The flange 48 m may include a first and second ends 49, 51 that areaxially and radially spaced apart from each other. The space between thefirst and second ends 49, 51 may define a first cutout 53 disposedapproximately one-hundred-eighty degrees (180°) apart from a secondcutout 55 in the flange 48 m. The first and second cutouts 53, 55 maycooperate to define first and second portions 57, 59 of the flange 48 m.

With continued reference to FIGS. 25-27, assembly of the reclinermechanism 10 m to the seatback-side member 12 m will be described indetail. Once the guide plate 14, ratchet plate 16, and locking mechanism18 are attached to the encapsulation ring 20 m, the recliner mechanism10 m may be engaged with the aperture 36 m of the seatback-side member12 m.

Engaging the recliner mechanism 10 m with the aperture 36 m may includepositing the recliner mechanism 10 m so that the encapsulation ring 20 mis substantially coaxial with the aperture 36 m and axially positionedso that the second portion 41 of the second flange 30 m of theencapsulation ring 20 m is abutting the first portion 57 of the flange48 m. The recliner mechanism 10 m can then be rotated approximatelyone-hundred-eighty degrees (180°) to thread the helical surfaces of thesecond flange 30 m and the flange 48 m into a position in which thesecond portion 59 of the flange 48 m engages the second portion 41 ofthe second flange 30 m, as shown in FIGS. 25 and 27. Such aconfiguration allows the recliner mechanism 10 m and encapsulation ring20 m to be assembled to the seat-back side member 12 m in a directiontoward surfaces 38, 40.

Once the recliner mechanism 10 m is positioned in this manner relativeto the seatback-side member 12 a, one or more welds may be applied tothe second flange 30 m and the flange 48 m to fix the encapsulation ring20 m relative to the seatback-side member 12 a. In some embodiments, thepitches of the flanges 30 m, 48 m can be configured such that more orless rotation of the encapsulation ring 20 m relative to the aperture 36m than described above is needed to fully engage the flanges 30 m, 48 mwith each other.

As with the recliner mechanism 10, during operation, the ratchet plate16 of the recliner mechanism 10 m may be fixed for rotation with theseatback-side member 12 m due to engagement between the ratchet plate 16and the encapsulation ring 20 m. The encapsulation ring 20 m may befixedly attached to the ratchet plate 16 via one or more welds.Attaching the encapsulation ring 20 m in this manner fixes the ratchetplate 16 and encapsulation ring 20 m for movement with the seatback-sidemember 12 m relative to the seat-bottom side member 13.

With reference to FIGS. 28 and 29, a recliner mechanism 10 n is shownincorporated into a seatback-side member 12 n. In view of thesubstantial similarity in structure and function of the componentsassociated with the recliner mechanism 10 and seatback-side member 12with respect to the components associated with the recliner mechanism 10n and seatback-side member 12 n, like reference numerals are usedhereinafter in the drawings to identify like components while likereference numerals containing letter extensions are used to identifythose components that have been modified.

As with the recliner mechanism 10, the recliner mechanism 10 n mayinclude a guide plate 14, a ratchet plate 16, and a locking mechanism18. The recliner mechanism 10 n may also include an encapsulation ring20 n including a main body 26 n, a first flange 28 n, and a secondflange 30 n. The main body 26 n may be formed substantiallyperpendicular to the first and second flanges 28 n, 30 n and may extendaround at least a portion of an outer perimeter of the guide plate 14and the ratchet plate 16. The first and second flanges 28 n, 30 n mayextend radially from the main body 26 n in opposite directions from eachother. The second flange 30 n may include a plurality of apertures 96formed therethrough.

The seatback-side member 12 n may include a main body 32 n including anaperture 36 n and first, second, third and fourth surfaces 38 n, 40 n,42 n, 44 n. One or both of the third and fourth surfaces 42 n, 44 n mayinclude one or more protrusions 98 extending outwardly therefrom in adirection generally parallel to an axis defining the aperture 36 n. Theprotrusions 98 can be formed by pressing dimples in the first and secondsurfaces 38 n, 40 n, for example. The number of protrusions 98 and thespacing therebetween may correspond to the number of apertures 96 in theencapsulation ring 20 n and the relative spacing between the apertures96, respectively.

With continued reference to FIGS. 28 and 29, attachment of the reclinermechanism 10 n to the seatback-side member 12 n will be described indetail. Once the recliner mechanism 10 n is assembled such that theguide plate 14, ratchet plate 16, and locking mechanism 18 are assembledto the encapsulation ring 20 n, the recliner mechanism 10 n may beattached to the seatback-side member 12 n. The recliner mechanism 10 nmay be inserted into the aperture 36 n until the second flange 30 n ofthe encapsulation ring 20 n contacts the third and fourth surfaces 42 n,44 n with the protrusions 98 of the seatback-side member 12 n engagingthe apertures 96 in the second flange 30 n. Engagement between theprotrusions 98 and apertures 96 may facilitate rotational alignment ofthe recliner mechanism 10 n relative to the seatback-side member 12 n.

The engagement between the protrusions 98 and the apertures 96 may be apress fit or interference fit, so that once the encapsulation ring 20 nis pressed into engagement with the seatback-side member 12 n, therecliner mechanism 10 n may be securely retained on the seatback-sidemember 12 n. In some embodiments, rivets may be used in addition to orin the alternative to the protrusions 98 to secure the encapsulationring 20 n to the seatback-side member 12 n. In some embodiments, one ormore welds may be applied to the encapsulation ring 20 n and theseatback-side member 12 n to secure the recliner mechanism 10 n to theseatback-side member 12 n. The one or more welds may be appliedproximate the apertures 96 and protrusions 98, proximate the aperture 36n and the main body 26 n and/or second flange 30 n, and/or proximate anouter perimeter of the second flange 30 n and the third and/or fourthsurfaces 42 n, 44 n.

While various embodiments of the recliner mechanism 10-10 n are shown inthe figures and described above as being in a particular orientationrelative to the seatback-side member 12-12 n, in some embodiments, therecliner mechanism 10-10 n could be oriented differently. For example,the recliner mechanism 10 is shown in FIGS. 4 and 5 being oriented suchthat the ratchet plate 16 faces an interior of the seat assembly 2 andthe guide plate 14 and first flange 28 face outwardly from the seatassembly 2. In some embodiments, however, the orientation of therecliner mechanism 10 relative to the seatback-side member 12 could bereversed such that the guide plate 14 and first flange 28 face theinterior of the seat assembly 2 and the ratchet plate 16 faces outwardlyfrom the seat assembly 2.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the invention. Individual elements or features ofa particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the invention, and all such modificationsare intended to be included within the scope of the invention.

1. A seat assembly comprising: a support member including a firstsurface, a second surface, and an aperture disposed between said firstsurface and said second surface, said first surface being substantiallycoplanar with said second surface; and a recliner mechanism receivedbetween said first surface and said second surface and at leastpartially overlapping said aperture.
 2. The seat assembly of claim 1,wherein at least a portion of said recliner mechanism extends into saidaperture.
 3. The seat assembly of claim 1, wherein said reclinermechanism includes an encapsulation ring extending at least partiallyaround a perimeter of said recliner mechanism.
 4. The seat assembly ofclaim 3, wherein a first end of said encapsulation ring at leastpartially extends into said aperture.
 5. The seat assembly of claim 4,wherein said encapsulation ring includes a first helically shaped flangeand said support member includes a second helically shaped flangedisposed coaxially with said aperture, said first flange engaging saidsecond flange.
 6. The seat assembly of claim 4, wherein said first endis welded to said support member proximate to said aperture andproximate to at least one of said first surface and said second surface.7. The seat assembly of claim 1, further comprising a flange integrallyformed with said first surface and said second surface and defining athird surface substantially perpendicular to said first surface and saidsecond surface.
 8. The seat assembly of claim 7, wherein said reclinermechanism includes an encapsulation ring, said encapsulation ringextending into said aperture and substantially parallel to said thirdsurface.
 9. The seat assembly of claim 8, wherein said encapsulationring is fixedly attached to said third surface of said flange.
 10. Theseat assembly of claim 1, wherein said support member includes a doublerplate and at least a portion of said recliner mechanism is fixedlyattached to said doubler plate.
 11. A seat assembly comprising: asupport member including a first surface, a second surface, and anaperture disposed between said first surface and said second surface,said first surface being substantially coplanar with said secondsurface; a recliner mechanism received between said first surface andsaid second surface and disposed substantially coaxial with saidaperture; and an encapsulation member engaging said support member andsaid recliner mechanism.
 12. The seat assembly of claim 11, wherein saidencapsulation member engages said aperture in said support member. 13.The seat assembly of claim 12, wherein at least a portion of saidrecliner mechanism extends into said aperture.
 14. The seat assembly ofclaim 12, wherein said encapsulation member includes a flange engagingsaid support member.
 15. The seat assembly of claim 14, wherein saidflange includes a substantially helical shape and engages a helicallyshaped member of said support member that is substantially coaxial withsaid aperture.
 16. The seat assembly of claim 11, wherein saidencapsulation member includes an annular portion extending at leastpartially around a perimeter of said recliner mechanism.
 17. The seatassembly of claim 16, wherein a first end of said encapsulation ring atleast partially extends into said aperture in said support member, saidfirst end being welded to said support member proximate to said apertureand proximate to at least one of said first surface and said secondsurface.
 18. The seat assembly of claim 11, further comprising a flangeintegrally formed with said first surface and said second surface anddefining a third surface substantially perpendicular to said firstsurface and said second surface, said encapsulation member extendinginto said aperture and substantially parallel to said third surface. 19.The seat assembly of claim 11, wherein said support member includes adoubler plate and at least a portion of said recliner mechanism isfixedly attached to said doubler plate.
 20. The seat assembly of claim11, wherein said support member is a seatback support member.